US20100325875A1 - Apparatus and methods for winding supports for coils and single poles of cores of dynamo electric machines - Google Patents
Apparatus and methods for winding supports for coils and single poles of cores of dynamo electric machines Download PDFInfo
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- US20100325875A1 US20100325875A1 US12/919,659 US91965909A US2010325875A1 US 20100325875 A1 US20100325875 A1 US 20100325875A1 US 91965909 A US91965909 A US 91965909A US 2010325875 A1 US2010325875 A1 US 2010325875A1
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- Prior art keywords
- wire
- coil support
- dispensing member
- rotation
- wound
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Classifications
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
- H02K15/08—Forming windings by laying conductors into or around core parts
- H02K15/095—Forming windings by laying conductors into or around core parts by laying conductors around salient poles
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/064—Winding non-flat conductive wires, e.g. rods, cables or cords
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/082—Devices for guiding or positioning the winding material on the former
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49009—Dynamoelectric machine
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/53—Means to assemble or disassemble
- Y10T29/5313—Means to assemble electrical device
- Y10T29/53143—Motor or generator
- Y10T29/53161—Motor or generator including deforming means
Definitions
- the present invention relates to winding coils of dynamo electric machines.
- the solutions of the invention concern winding coil supports or single poles where one or more electric conductors (in the following also referred to as wire) are wound to form a predetermined number of turns of a coil.
- the supports for coils are made of insulation material and are assembled on the poles of cores after having being wound. Supports of this type have been described in JP 2003-244906.
- Single poles are portions of the core and are disassembled from the core when they are wound. After winding, the single poles are assembled one adjacent to the other to form the core; see EP 1098425.
- coil support contemplates both the supports for coils and single poles.
- the wire that needs to be wound can have a large cross section, therefore if it undergoes bending this will remain as a permanent deformation if it is not recovered with further bending of the wire.
- the wire is deformed to be in contact with the surface of the coil support, or to be in contact with portions of wires which have already been wound on the coil support.
- the deformation process bends the wire according to a configuration that tries to closely match the shape of the perimeter of the coil support where the wire turns are wound. This is done to optimize the amount of wire that can be wound in a given space of the coil support.
- Winding can occur by rotating the coil support to draw the wire from the exit of a dispensing member and by directing the wire from the dispensing member to predetermined locations of the coil support.
- winding can occur by displacing the dispensing member to draw and direct the wire.
- JP 2003-244906 describes a mechanism consisting of a winding arm which rotates to draw and locate the wire on the coil support.
- the solution of this document provides a pressure member, which presses on the wire that has been wound to maintain it in contact with the coil support during rotation.
- the integrity of the wire that is being wound needs to be guaranteed.
- damage to the insulation of the wire needs to be avoided and the wire should not be subject to high local deformations.
- the damage if present, can be a source for early failure of the dynamo electric machine.
- the method for winding the coil support provides the steps of:
- FIG. 1 is a partial elevational view illustrating the solution of the invention according to a first embodiment in a condition of winding like that shown in FIG. 2A .
- FIG. 1 is a view from direction 1 of FIG. 2A .
- FIGS. 2A-2E are views from direction 2 of FIG. 1 and illustrate a sequence of winding conditions obtained with the solution of the invention to wind a turn of wire on a coil support.
- FIG. 2F is a view similar to the view of FIG. 1 and illustrates a condition of winding which occurs after the condition of FIG. 2E .
- FIG. 3 is a perspective view from direction 3 of FIG. 2A illustrating a coil support that has been wound with a predetermined number of turns by using the solution of the invention.
- FIG. 4 is a view similar to the view of FIG. 2F and shows winding a single pole according to a solution of the invention.
- FIG. 5 is a partial sectional view from directions 5 - 5 of FIG. 4 .
- FIG. 6 is a partial sectional view from directions 6 - 6 of FIG. 7 .
- FIG. 7 is a view similar to FIG. 1 illustrating an embodiment of the invention.
- FIG. 8 is a view similar to FIG. 7 that illustrates winding a single pole according to a further embodiment of the invention.
- FIG. 9 is a view similar to the view of FIG. 2B illustrating a further embodiment of the invention performing a winding stage like that of FIG. 2B .
- the apparatus of the invention is provided with an assembly 29 for holding and rotating a coil support 10 .
- the assembly comprises a holding member 21 , which becomes inserted in hollow portion 10 ′ of coil support 10 .
- Coil support 10 comprises a central portion 12 and opposite flanges 12 ′ and 12 ′′.
- Wire W is wound around portion 12 up to flanges 12 ′ and 12 ′′ to form a coil C of a certain number of turns, as shown in FIG. 3 .
- FIGS. 2A-2E superior flange 12 ′ has been made transparent to show parts that would otherwise be hidden in the views from direction 2 .
- member 21 applies a grip on the internal surface of hollow portion 10 ′ to hold coil support 10 in alignment with rotation axis 11 .
- Axis 11 can be aligned with an axis of symmetry of the coil support, as shown in FIGS. 1 , 2 A- 2 E.
- coil support 10 rotates with rotation R around axis 11 by rotating holding member 21 with drive unit 25 .
- wire W is delivered by dispensing member 19 , which receives wire W from a wire supply (not shown).
- wire W runs though passage 22 of dispensing member 19 and leaves dispensing member 19 through exit 23 to reach coil support 10 .
- Dispensing member 19 is assembled on platform 24 so that exit 23 faces coil support 12 .
- Exit 23 is provided with a solid contour for guiding the wire.
- Platform 24 can be displaced in direction Y and Y′ by sliding on guide 24 ′. Movement of platform 24 in directions Y and Y′ changes the distance between dispensing member 19 and axis 11 , which represents the reference for rotation of the coil support.
- FIG. 1 provides a pressure wheel 13 that is supported by arms 14 (see also FIG. 2A ).
- the pressure wheel can be idle in its rotation around axis 15 of arms 14 .
- Arms 14 are carried by platform 16 , which can move in directions X and X′ by sliding on guide 16 ′.
- Guides 16 ′ can be carried by platform 17 , which can move in direction Y and Y′ by sliding on guides 17 ′.
- Guides 17 ′ can be part of a further platform 18 which moves when required in directions Z and Z′ by sliding on guides 18 ′ of the apparatus frame.
- pressure wheel 13 is capable of moving in directions X, X, Y, Y′, Z, Z′ with respect to a stationary origin, like a point of rotation axis 11 .
- the initial portion W′ of wire W is anchored by a wire manipulator in a recess of the coil support 10 (as shown in the figures), or the initial portion W′ is anchored in a clamping device that rotates with holding member 21 (not shown in the figures). In this way, initial portion W′ remains stationary with respect to the coil support 10 and therefore wire W is drawn from dispensing member 19 by means of rotation R of the coil support around axis 11 .
- exit 23 of dispensing member is aligned with side 12 a of the coil support.
- the alignment is such that wire extension WE from exit 23 to side 12 A of the coil support is oriented without bending the wire coming out from exit 23 . Therefore, the extension of wire WE is not inclined with respect to exit 23 , in order to avoid bending the wire where the contact occurs with the contour of exit 23 .
- pressure wheel 13 can press on a wire portion WP that is immediately adjacent to a portion of the wire that still has to be wound on the coil support. In this way, the wire is deformed against the coil support practically from when the wire starts contact with the coil support.
- FIGS. 2B and 2C show that coil support 12 has been rotated to draw further wire W on side 12 a and on transverse side 12 c of the coil support.
- wheel 13 moves in directions X and Y to keep the deformation pressure on wire portion WP, which is located immediately adjacent to the portion of wire that still has to be wound on the coil support. In this way the wire continues to be deformed against the coils practically from when the wire starts to contact the coil support.
- the point WP is like a point of tangency of wire WE with the shape of the coil that progressively becomes wound on the coils support.
- dispensing member 19 has moved more and more in direction Y during the rotation of the coil support to maintain constant the orientation of wire extension WE and therefore to avoid bending the wire at exit 23 .
- the angle of extension WE is maintained constant with respect to exit 23 .
- FIG. 2D shows the condition in which the coil support has rotated for a complete turn and pressure wheel has moved in direction X and direction Y′.
- dispensing member 19 has moved in direction Y′ to maintain constant the orientation of extension WE.
- the pressure wheel starts a translation in direction X′ to reach the position shown in FIG. 2E .
- pressure wheel 13 can continue to press on the portion of wire that has been directed along side 12 b .
- the speed for translating pressure wheel 13 along side 12 b can be higher than the speed normally used to translate the pressure wheel in the other translations of FIGS. 2A-2C . This occurs to avoid that the pressure wheel loses time for reaching the appointment for continuing rotation R of the coil support, as it is required in the situation of FIG. 2E .
- dispensing member 19 can be translated in direction Z′ (see FIG. 2F ) by using platform 27 moving on guides 27 ′ for directing the successive turn of wire with a transition stretch WT in a second winding plane 11 b , which is perpendicular to axis 11 (see dashed line representation of wire WT in FIG. 2F ).
- the pressure wheel can be moved in direction Z′ in such a way that it is synchronized with the translation of dispensing member in direction Z′, in order to guarantee that the pressure wheel remains in contact and presses on wire WT that winds around the transverse portion 12 d .
- FIG. 2F shows an engagement member 26 positioned for engaging the last stretch of wire WF of the first winding plane.
- the engagement is required if the last stretch of wire WF tries to exit from the first winding plane.
- the exit of the wire WF from the first winding plane can occur, for example, when pressure wheel 13 and dispensing member 19 are moved in direction Z′ to form stretch WT.
- Engagement member 26 is adapted to rotate integral with coil support 10 , and when required it translates in directions Z and Z′ to support the various wires that need to be deposited along portion 12 in directions Z and Z′, like it has been described above. Therefore, support member 26 supports the various wire by acting as a barrier against their movement in the direction of stratification (direction Z′ in the case of FIG. 2F ).
- the devices for accomplishing the motions of member 26 comprise a support arm 28 .
- the arm 28 is provided with a hub portion 28 ′ assembled coaxially to the rotation shaft 30 of holding member 21 .
- Key 30 ′ present on shaft 30 is engaged by a key portion 31 of the hub for transmitting to arm 28 the rotation R of shaft 29 .
- a drive member (not shown) can translate the hub portion along shaft 30 in directions Z and Z′ to translate support member 26 in directions Z and Z′, as it is required to position member 26 to function as a barrier against movement of the single wires that need to be deposited along portion 12 within a layer of the coil.
- the definition “layer of the coil” has the meaning of turns wounds after one another to become positioned practically at the same distance from axis 11 .
- FIGS. 4 and 5 show a single pole 40 that is wound in a manner that is similar to the description of FIGS. 1-3 .
- the single pole can be held with chucks 33 ′ and 33 ′′ which can rotate around axis 11 .
- the single pole has sides like 12 a , 12 b , 12 c , 12 d described above for the coil support 10 .
- the pressure exerted by wheel 13 on the wire can be adjusted in a predetermined manner using the control of the movements of platform 17 , which is needed for translation in directions Y and Y′.
- Control of the pressure applied by wheel 13 if synchronized with the motion law of rotation R of the coil support, allows a predetermined and accurate pressure to be applied along the wire which is wound around the coil support.
- dispensing member 19 using platforms 24 and 27 can be synchronized with the law of motion of rotation R of the coil support to guarantee that the orientation of extension WE, or in other terms that the angle of extension WE, remains constant with respect to exit 23 .
- a sequence of conditions like those of FIG. 2A-2F can be repeated both for coil support 10 and for single pole 40 , in order to form successive turns of wire in further planes. This accomplishes stratification of the wire along portion 12 , as shown in FIG. 3 for coil support 10 .
- a particular embodiment of the invention provides holding member 21 that is adapted to hold coil support 10 , where the holding member is fixed to shaft 50 for rotation R′ around axis 50 ′.
- Axis 50 ′ can be perpendicular to rotation axis 11 that is required for rotation R accomplished during winding.
- Shaft 50 can be assembled on bearings 51 of support member 52 .
- Support member 52 can be fixed to the end of shaft 53 , which is assembled on bearings 53 ′′ of frame member 61 .
- Axis 53 ′ of shaft 53 can be in alignment with rotation axis 11 , such that the rotation of shaft 53 on bearings 53 ′′ accomplishes the rotation R of coil support 10 around axis 11 (see also FIG. 7 ) that is necessary for winding.
- Hollow member 54 can be assembled on bearings 55 of frame member 61 to be coaxial to shaft 53 , as shown in FIG. 6 . Consequently, hollow member 54 can accomplish rotation R′′ around axis 53 ′. End portion 54 ′ of hollow member 54 can carry a crown gear 56 , as shown in FIG. 6 . Crown gear 56 can engage a pinion gear 57 that is assembled on a shaft 58 . Shaft 58 is supported for rotation on support member 52 , as shown in FIG. 6 . A belt transmission 59 transmits rotation of shaft 58 to shaft 50 .
- FIG. 7 shows a rotation R′ of holding member 21 around axis 50 ′ due to a rotation R′′ around axis 53 ′ of hollow member 54 .
- This rotation R′ has an inclined axis of symmetry 60 of coil support 10 with respect to axis of rotation 11 and to axis 53 ′.
- the resulting position of coil support 10 due to rotation R′ can be used to incline wire W, for example on a transverse or shorter side like 12 C of coil support 10 , in order to form a transition portion WT of wire W going from a complete turn to another in a direction like 60 ′ (i.e. parallel to axis 60 ), as shown in FIG. 7 .
- wheel 13 moves to maintain the deformation pressure on transition portion WT.
- the deformation pressure is applied on the wire portions of transition portion WT, which are immediately adjacent to the wire that still has to be wound on the coil support. In this way, the wire that forms transition portion WT can be permanently deformed and positioned against the coil support.
- dispensing member 19 can be moved during the rotation of the coil support and the inclination of the coils support as shown in FIG. 7 , so as to maintain constant the orientation of wire extension WE.
- transition portion WT has been completed and wheel 13 applies pressure on the wire that is wound along side 12 d .
- a pressure is applied in direction K having an angle E with respect to axis 60 of coil support 10 .
- Angle E is not perpendicular to axis 60 of the coil support. In particular angle E can be less than perpendicular and more than zero, as shown in FIG. 7 , therefore the pressure exerted by wheel 13 has a component that presses on portion WZ of wire W, to maintain portion WZ in position against flange 12 ′′.
- FIG. 8 shows the single pole 40 that is being wound in a manner which is similar to the description of FIGS. 6 and 7 .
- Rotation R′ of chucks 33 ′ and 33 ′′ around axis 50 ′ has an inclined axis 70 of single pole 40 with respect to axis of rotation 11 and to axis 53 ′.
- This position of the single pole allows wheel 13 to be received very near to circumference portion 40 ′ of single pole 40 , where wheel 13 is able to press on an initial wire portion like WZ to press it against circumference portion 40 ′ of single pole 40 .
- FIG. 9 which is a view similar to the view of FIG. 2B , illustrates a further embodiment of the invention where pressure wheel 13 and dispensing members 19 are both carried by platform 16 .
- pressure wheel 13 is positioned by means of arm 90 on platform 16 and dispensing member 19 is oriented on platform 16 so that pressure wheel 13 is pressing on a wire portion WP that is immediately adjacent to a portion of the wire that still has to be wound on the coil support.
- FIG. 9 which is a view similar to the view of FIG. 2B , illustrates a further embodiment of the invention where pressure wheel 13 and dispensing members 19 are both carried by platform 16 .
- pressure wheel 13 is positioned by means of arm 90 on platform 16 and dispensing member 19 is oriented on platform 16 so that pressure wheel 13 is pressing on a wire portion WP that is immediately adjacent to a portion of the wire that still has to be wound on the coil support.
- an example of an alternative solution for the relative motion of dispensing member 19 with respect to coil support 10 or the single pole 40 , for maintaining the angular orientation of extension WE constant during winding can provide moving the coils support 10 or single pole 40 in direction Y e Y′. For example by translating in directions Y and Y′ rotation axis 11 , which at the same time will remain parallel to directions Z and Z′.
- coil support 10 or single pole 40 can move in directions X′ and X, Y and Y′, Z and Z′, by translating in such directions the rotation axis 11 .
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Abstract
Description
- The present invention relates to winding coils of dynamo electric machines.
- In particular the solutions of the invention concern winding coil supports or single poles where one or more electric conductors (in the following also referred to as wire) are wound to form a predetermined number of turns of a coil.
- The supports for coils are made of insulation material and are assembled on the poles of cores after having being wound. Supports of this type have been described in JP 2003-244906.
- Single poles are portions of the core and are disassembled from the core when they are wound. After winding, the single poles are assembled one adjacent to the other to form the core; see EP 1098425.
- In the following the use of the terminology “coil support” contemplates both the supports for coils and single poles.
- The wire that needs to be wound can have a large cross section, therefore if it undergoes bending this will remain as a permanent deformation if it is not recovered with further bending of the wire.
- During winding the wire is deformed to be in contact with the surface of the coil support, or to be in contact with portions of wires which have already been wound on the coil support.
- The deformation process bends the wire according to a configuration that tries to closely match the shape of the perimeter of the coil support where the wire turns are wound. This is done to optimize the amount of wire that can be wound in a given space of the coil support.
- Winding can occur by rotating the coil support to draw the wire from the exit of a dispensing member and by directing the wire from the dispensing member to predetermined locations of the coil support.
- Alternatively, winding can occur by displacing the dispensing member to draw and direct the wire. JP 2003-244906 describes a mechanism consisting of a winding arm which rotates to draw and locate the wire on the coil support. The solution of this document provides a pressure member, which presses on the wire that has been wound to maintain it in contact with the coil support during rotation.
- Modern applications of dynamo electric machine cores require that the quantity of wire that fills an allocated space of the coil support should be very high.
- Furthermore, to achieve this maximum result the integrity of the wire that is being wound needs to be guaranteed. In particular, damage to the insulation of the wire needs to be avoided and the wire should not be subject to high local deformations. The damage, if present, can be a source for early failure of the dynamo electric machine.
- Accordingly, it is an object of the present invention to position the wire accurately in predetermined locations of the coil support during winding to form a coil.
- It is a further object of the present invention to guarantee that the wire wound on the coil support is accurately deformed to be positioned along predetermined trajectories of the coil support, thereby increasing the filling.
- It is also an object of the present invention to apply an accurate and predetermined deformation along the wire during winding to guarantee maximum filling and the integrity of the wire.
- These and other objects are achieved with the apparatus according to
apparatus claim 1 and the method according toclaim 14 of the present invention. - Other characteristics of the inventions are presented in the dependent claims.
- According to an embodiment of the invention the apparatus comprises:
-
- means for rotating the coil support relative to the dispensing member to wind the wire on the coil support, and
- means for pressing on a portion of the wire that has been wound on the coil support, wherein during winding the pressing means remains in contact with a wire portion located on the coil support immediately adjacent to portions of the wire that still have to be wound on the coil support.
- In an embodiment of the invention the method comprises the steps of:
-
- rotating the coil support with respect to the dispensing member to wind the wire on the coil support;
- using pressing means for pressing on a portion of wire wound on the coil support, wherein during winding the pressing means remains in contact with a wire portion that is immediately adjacent to portions of the wire that still have to be wound on the coil support.
- According to another embodiment the apparatus for winding the coil support comprises:
-
- a dispensing member having a portion for passage of the wire and an exit from where the wire reaches the coil support during winding;
- means for rotating the coil support with respect to the dispensing member to wind the wire on the coil support; the wire extending from the dispensing member to the coil support having an angular orientation with respect to the exit of the dispenser; and
- means for the relative movement of the dispensing member with respect to the coil support to maintain the angular orientation constant during winding.
- According to this other embodiment, the method for winding the coil support provides the steps of:
-
- rotating the coil support with respect to the dispensing member to wind the wire onto the coil support; the wire extending from the dispensing member to the coil support having an angular orientation with respect to the exit of the dispensing member; and
- relatively moving the dispensing member with respect to the coil support to maintain the angular orientation constant during winding.
- In a further embodiment the apparatus for winding the coil support comprises:
-
- a dispensing member having a portion for passage of the wire and an exit from where the wire reaches the coil support during winding;
- means for rotating the coil support with respect to the dispensing member to wind the wire on the coil support;
- means for displacing the dispensing member with respect to the coil support for stratifying the wire of the coil, and
- means for engaging the portion of wire wound on the coil support that extends up to the dispensing member; the engagement occurring opposite to the direction of wire stratification for the wires of a layer of a coil.
- In a further embodiment the method provides:
-
- rotating the coil support with respect to the dispensing member to wind the wire on the coil support;
- displacing the dispensing member with respect to the coil support for stratifying the wire of the coil;
- engaging the portion of wire wound on the coil support that extends to the dispensing member, wherein the engagement occurs opposite to the direction of wire stratification for the wires of a layer of a coil.
- Further characteristics and advantages of the method and apparatus according to the invention will be more apparent from the following detailed description and the accompanying drawings of the preferred embodiments, which is made to be exemplary without being limitative. In the drawings:
-
FIG. 1 is a partial elevational view illustrating the solution of the invention according to a first embodiment in a condition of winding like that shown inFIG. 2A .FIG. 1 is a view fromdirection 1 ofFIG. 2A . -
FIGS. 2A-2E are views fromdirection 2 ofFIG. 1 and illustrate a sequence of winding conditions obtained with the solution of the invention to wind a turn of wire on a coil support. -
FIG. 2F is a view similar to the view ofFIG. 1 and illustrates a condition of winding which occurs after the condition ofFIG. 2E . -
FIG. 3 is a perspective view fromdirection 3 ofFIG. 2A illustrating a coil support that has been wound with a predetermined number of turns by using the solution of the invention. -
FIG. 4 is a view similar to the view ofFIG. 2F and shows winding a single pole according to a solution of the invention. -
FIG. 5 is a partial sectional view from directions 5-5 ofFIG. 4 . -
FIG. 6 is a partial sectional view from directions 6-6 ofFIG. 7 . -
FIG. 7 is a view similar toFIG. 1 illustrating an embodiment of the invention. -
FIG. 8 is a view similar toFIG. 7 that illustrates winding a single pole according to a further embodiment of the invention. -
FIG. 9 is a view similar to the view ofFIG. 2B illustrating a further embodiment of the invention performing a winding stage like that ofFIG. 2B . - With reference to
FIGS. 1 and 2 the apparatus of the invention is provided with anassembly 29 for holding and rotating acoil support 10. The assembly comprises a holdingmember 21, which becomes inserted inhollow portion 10′ ofcoil support 10. -
Coil support 10 comprises acentral portion 12 andopposite flanges 12′ and 12″. Wire W is wound aroundportion 12 up toflanges 12′ and 12″ to form a coil C of a certain number of turns, as shown inFIG. 3 . - In
FIGS. 2A-2E superior flange 12′ has been made transparent to show parts that would otherwise be hidden in the views fromdirection 2. - With reference to
FIG. 2A ,member 21 applies a grip on the internal surface ofhollow portion 10′ to holdcoil support 10 in alignment withrotation axis 11.Axis 11 can be aligned with an axis of symmetry of the coil support, as shown inFIGS. 1 , 2A-2E. During winding,coil support 10 rotates with rotation R aroundaxis 11 by rotating holdingmember 21 withdrive unit 25. - As shown in
FIGS. 2A-2F , wire W is delivered by dispensingmember 19, which receives wire W from a wire supply (not shown). - During winding, wire W runs though
passage 22 of dispensingmember 19 andleaves dispensing member 19 throughexit 23 to reachcoil support 10. Dispensingmember 19 is assembled onplatform 24 so thatexit 23 facescoil support 12.Exit 23 is provided with a solid contour for guiding the wire. -
Platform 24 can be displaced in direction Y and Y′ by sliding onguide 24′. Movement ofplatform 24 in directions Y and Y′ changes the distance between dispensingmember 19 andaxis 11, which represents the reference for rotation of the coil support. - The embodiment of
FIG. 1 provides apressure wheel 13 that is supported by arms 14 (see alsoFIG. 2A ). The pressure wheel can be idle in its rotation aroundaxis 15 ofarms 14.Arms 14 are carried byplatform 16, which can move in directions X and X′ by sliding onguide 16′.Guides 16′ can be carried byplatform 17, which can move in direction Y and Y′ by sliding onguides 17′.Guides 17′ can be part of afurther platform 18 which moves when required in directions Z and Z′ by sliding onguides 18′ of the apparatus frame. - Accordingly,
pressure wheel 13 is capable of moving in directions X, X, Y, Y′, Z, Z′ with respect to a stationary origin, like a point ofrotation axis 11. - To start winding a turn of wire on
portion 12 of the coil support (seeFIG. 2A ), the initial portion W′ of wire W is anchored by a wire manipulator in a recess of the coil support 10 (as shown in the figures), or the initial portion W′ is anchored in a clamping device that rotates with holding member 21 (not shown in the figures). In this way, initial portion W′ remains stationary with respect to thecoil support 10 and therefore wire W is drawn from dispensingmember 19 by means of rotation R of the coil support aroundaxis 11. - As shown in
FIG. 2A , exit 23 of dispensing member is aligned withside 12 a of the coil support. The alignment is such that wire extension WE fromexit 23 to side 12A of the coil support is oriented without bending the wire coming out fromexit 23. Therefore, the extension of wire WE is not inclined with respect to exit 23, in order to avoid bending the wire where the contact occurs with the contour ofexit 23. - As shown in
FIG. 2A ,pressure wheel 13 can press on a wire portion WP that is immediately adjacent to a portion of the wire that still has to be wound on the coil support. In this way, the wire is deformed against the coil support practically from when the wire starts contact with the coil support. -
FIGS. 2B and 2C show thatcoil support 12 has been rotated to draw further wire W onside 12 a and ontransverse side 12 c of the coil support. During the rotation R,wheel 13 moves in directions X and Y to keep the deformation pressure on wire portion WP, which is located immediately adjacent to the portion of wire that still has to be wound on the coil support. In this way the wire continues to be deformed against the coils practically from when the wire starts to contact the coil support. In other words the point WP is like a point of tangency of wire WE with the shape of the coil that progressively becomes wound on the coils support. - At the same time, dispensing
member 19 has moved more and more in direction Y during the rotation of the coil support to maintain constant the orientation of wire extension WE and therefore to avoid bending the wire atexit 23. In other words the angle of extension WE is maintained constant with respect toexit 23. -
FIG. 2D shows the condition in which the coil support has rotated for a complete turn and pressure wheel has moved in direction X and direction Y′. - Furthermore dispensing
member 19 has moved in direction Y′ to maintain constant the orientation of extension WE. InFIG. 2D the pressure wheel starts a translation in direction X′ to reach the position shown inFIG. 2E . During the translation,pressure wheel 13 can continue to press on the portion of wire that has been directed alongside 12 b. The speed for translatingpressure wheel 13 alongside 12 b can be higher than the speed normally used to translate the pressure wheel in the other translations ofFIGS. 2A-2C . This occurs to avoid that the pressure wheel loses time for reaching the appointment for continuing rotation R of the coil support, as it is required in the situation ofFIG. 2E . - After the situation of
FIG. 2E , dispensingmember 19 can be translated in direction Z′ (seeFIG. 2F ) by usingplatform 27 moving onguides 27′ for directing the successive turn of wire with a transition stretch WT in a second windingplane 11 b, which is perpendicular to axis 11 (see dashed line representation of wire WT inFIG. 2F ). The pressure wheel can be moved in direction Z′ in such a way that it is synchronized with the translation of dispensing member in direction Z′, in order to guarantee that the pressure wheel remains in contact and presses on wire WT that winds around thetransverse portion 12 d.FIG. 2F shows anengagement member 26 positioned for engaging the last stretch of wire WF of the first winding plane. The engagement is required if the last stretch of wire WF tries to exit from the first winding plane. The exit of the wire WF from the first winding plane can occur, for example, whenpressure wheel 13 and dispensingmember 19 are moved in direction Z′ to form stretch WT. -
Engagement member 26 is adapted to rotate integral withcoil support 10, and when required it translates in directions Z and Z′ to support the various wires that need to be deposited alongportion 12 in directions Z and Z′, like it has been described above. Therefore,support member 26 supports the various wire by acting as a barrier against their movement in the direction of stratification (direction Z′ in the case ofFIG. 2F ). - The devices for accomplishing the motions of
member 26 comprise asupport arm 28. Thearm 28 is provided with ahub portion 28′ assembled coaxially to therotation shaft 30 of holdingmember 21.Key 30′ present onshaft 30 is engaged by akey portion 31 of the hub for transmitting to arm 28 the rotation R ofshaft 29. -
Shaft 30 is moved bydrive unit 25. A drive member (not shown) can translate the hub portion alongshaft 30 in directions Z and Z′ to translatesupport member 26 in directions Z and Z′, as it is required to positionmember 26 to function as a barrier against movement of the single wires that need to be deposited alongportion 12 within a layer of the coil. The definition “layer of the coil” has the meaning of turns wounds after one another to become positioned practically at the same distance fromaxis 11. -
FIGS. 4 and 5 show asingle pole 40 that is wound in a manner that is similar to the description ofFIGS. 1-3 . The single pole can be held withchucks 33′ and 33″ which can rotate aroundaxis 11. The single pole has sides like 12 a, 12 b, 12 c, 12 d described above for thecoil support 10. - The relative movements of the
pressure wheel 13, of the dispensingmember 19 and of theengagement member 26 with respect to a single pole can occur like it has been described above for winding coil C as shown inFIG. 3 . - In general for the various embodiments, the pressure exerted by
wheel 13 on the wire can be adjusted in a predetermined manner using the control of the movements ofplatform 17, which is needed for translation in directions Y and Y′. Control of the pressure applied bywheel 13, if synchronized with the motion law of rotation R of the coil support, allows a predetermined and accurate pressure to be applied along the wire which is wound around the coil support. - Furthermore, the synchronization of the pressure wheel movements in directions X,X′,Y,Y′,Z,Z′ with the law of motion of rotation R allows deformations of the wire against the coil support practically from when the wire starts contact with the coil support; see portion WP. In other words it is possible to accomplish with constancy the condition that point WP is the point of tangency of wire WE with the profile of the coil support, or the point of tangency with shape of the coil which progressively winds onto the coil support.
- Also the movement of dispensing
member 19 usingplatforms exit 23. - A sequence of conditions like those of
FIG. 2A-2F can be repeated both forcoil support 10 and forsingle pole 40, in order to form successive turns of wire in further planes. This accomplishes stratification of the wire alongportion 12, as shown inFIG. 3 forcoil support 10. - With reference to
FIGS. 6 and 7 , a particular embodiment of the invention provides holdingmember 21 that is adapted to holdcoil support 10, where the holding member is fixed toshaft 50 for rotation R′ aroundaxis 50′.Axis 50′ can be perpendicular torotation axis 11 that is required for rotation R accomplished during winding.Shaft 50 can be assembled onbearings 51 ofsupport member 52.Support member 52 can be fixed to the end ofshaft 53, which is assembled onbearings 53″ offrame member 61.Axis 53′ ofshaft 53 can be in alignment withrotation axis 11, such that the rotation ofshaft 53 onbearings 53″ accomplishes the rotation R ofcoil support 10 around axis 11 (see alsoFIG. 7 ) that is necessary for winding. -
Hollow member 54 can be assembled onbearings 55 offrame member 61 to be coaxial toshaft 53, as shown inFIG. 6 . Consequently,hollow member 54 can accomplish rotation R″ aroundaxis 53′.End portion 54′ ofhollow member 54 can carry acrown gear 56, as shown inFIG. 6 .Crown gear 56 can engage apinion gear 57 that is assembled on ashaft 58.Shaft 58 is supported for rotation onsupport member 52, as shown inFIG. 6 . Abelt transmission 59 transmits rotation ofshaft 58 toshaft 50. - In this way, rotation R″ around
axis 53′ ofhollow member 54 is transmitted toshaft 50 for achieving rotation R′ of holdingmember 21 aroundaxis 50′, and therefore rotation R′ ofcoil support 10 aroundaxis 50′. The drive means for rotatinghollow member 54 andshaft 53 has not been shown for reasons of clarity. -
FIG. 7 shows a rotation R′ of holdingmember 21 aroundaxis 50′ due to a rotation R″ aroundaxis 53′ ofhollow member 54. This rotation R′ has an inclined axis ofsymmetry 60 ofcoil support 10 with respect to axis ofrotation 11 and toaxis 53′. The resulting position ofcoil support 10 due to rotation R′ can be used to incline wire W, for example on a transverse or shorter side like 12C ofcoil support 10, in order to form a transition portion WT of wire W going from a complete turn to another in a direction like 60′ (i.e. parallel to axis 60), as shown inFIG. 7 . - During the winding rotation R and with the inclination of the coil support as shown in
FIG. 7 ,wheel 13 moves to maintain the deformation pressure on transition portion WT. - The deformation pressure is applied on the wire portions of transition portion WT, which are immediately adjacent to the wire that still has to be wound on the coil support. In this way, the wire that forms transition portion WT can be permanently deformed and positioned against the coil support.
- At the same time, dispensing
member 19 can be moved during the rotation of the coil support and the inclination of the coils support as shown inFIG. 7 , so as to maintain constant the orientation of wire extension WE. - In
FIG. 7 , transition portion WT has been completed andwheel 13 applies pressure on the wire that is wound alongside 12 d. A pressure is applied in direction K having an angle E with respect toaxis 60 ofcoil support 10. Angle E is not perpendicular toaxis 60 of the coil support. In particular angle E can be less than perpendicular and more than zero, as shown inFIG. 7 , therefore the pressure exerted bywheel 13 has a component that presses on portion WZ of wire W, to maintain portion WZ in position againstflange 12″. -
FIG. 8 shows thesingle pole 40 that is being wound in a manner which is similar to the description ofFIGS. 6 and 7 . Rotation R′ ofchucks 33′ and 33″ aroundaxis 50′ has aninclined axis 70 ofsingle pole 40 with respect to axis ofrotation 11 and toaxis 53′. This position of the single pole allowswheel 13 to be received very near tocircumference portion 40′ ofsingle pole 40, wherewheel 13 is able to press on an initial wire portion like WZ to press it againstcircumference portion 40′ ofsingle pole 40. -
FIG. 9 , which is a view similar to the view ofFIG. 2B , illustrates a further embodiment of the invention wherepressure wheel 13 and dispensingmembers 19 are both carried byplatform 16. As shown inFIG. 9 ,pressure wheel 13 is positioned by means ofarm 90 onplatform 16 and dispensingmember 19 is oriented onplatform 16 so thatpressure wheel 13 is pressing on a wire portion WP that is immediately adjacent to a portion of the wire that still has to be wound on the coil support. In the embodiment ofFIG. 9 , by means of the movements ofplatforms pressure wheel 13 and dispensingmember 19 with common movements with respect torotation axis 11, in order to guarantee a pressure contact on the wire that is being wound around the coil support.Arm 90 can be moveable onplatform 16 to adjust the position ofpressure wheel 13 with respect to dispensingmember 19. - For the embodiments that have been described in the foregoing, an example of an alternative solution for the relative motion of dispensing
member 19 with respect tocoil support 10 or thesingle pole 40, for maintaining the angular orientation of extension WE constant during winding, can provide moving the coils support 10 orsingle pole 40 in direction Y e Y′. For example by translating in directions Y and Y′rotation axis 11, which at the same time will remain parallel to directions Z and Z′. - A similar situation occurs for the relative movement which changes the distance that separates
pressure wheel 13 fromrotation axis 11 of coil support during winding. In fact,coil support 10 orsingle pole 40 can move in directions X′ and X, Y and Y′, Z and Z′, by translating in such directions therotation axis 11. - The controls, the adjustments, the programming and the synchronizations described in the foregoing can be achieved using suitable means for automatic processing, logics and controls like those presently available to the skilled man.
- The foregoing description of specific embodiments will so fully reveal the invention according to the conceptual point of view, so that others, by applying current knowledge, will be able to modify and/or adapt for various applications such an embodiment without further research and without departing from the invention, and it is therefore to be understood that such adaptations and modifications will have to be considered as equivalent to the specific embodiment. The means and the materials to realise the different functions described herein could have a different nature without, for this reason, departing from the field of the invention. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation.
Claims (37)
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
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IT000023A ITPI20080023A1 (en) | 2008-03-19 | 2008-03-19 | EQUIPMENT AND METHODS FOR WINDING SUPPORTS FOR REELS AND SINGLE POLE NUCLEI FOR DYNAMIC ELECTRIC MACHINES |
ITPI2008A0023 | 2008-03-19 | ||
ITPI2008A000023 | 2008-03-19 | ||
PCT/EP2009/002002 WO2009115312A2 (en) | 2008-03-19 | 2009-03-18 | Apparatus and methods for winding supports for coils and single poles of cores of dynamo electric machines |
Publications (2)
Publication Number | Publication Date |
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US20100325875A1 true US20100325875A1 (en) | 2010-12-30 |
US9543813B2 US9543813B2 (en) | 2017-01-10 |
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US12/919,659 Active 2032-08-31 US9543813B2 (en) | 2008-03-19 | 2009-03-18 | Apparatus and methods for winding supports for coils and single poles of cores of dynamo electric machines |
Country Status (10)
Country | Link |
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US (1) | US9543813B2 (en) |
EP (1) | EP2266193B1 (en) |
KR (1) | KR101392465B1 (en) |
CN (1) | CN101978582B (en) |
DK (1) | DK2266193T3 (en) |
ES (1) | ES2664577T3 (en) |
IT (1) | ITPI20080023A1 (en) |
SI (1) | SI2266193T1 (en) |
TR (1) | TR201802294T4 (en) |
WO (1) | WO2009115312A2 (en) |
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KR20140022030A (en) * | 2011-05-16 | 2014-02-21 | 어탑 에스.피.에이. | Apparatus and method for manufacturing coil members for cores of dynamo electric machines by bending |
US9455614B2 (en) | 2011-03-07 | 2016-09-27 | Atop S.P.A. | Method for aligning conductors of coil members |
US9467029B2 (en) | 2010-06-21 | 2016-10-11 | Atop S.P.A. | Apparatus and method for winding supports for coils and single poles of cores for dynamoelectric machines |
KR20160131056A (en) * | 2014-03-07 | 2016-11-15 | 어탑 에스.피.에이. | Apparatus and method for forming coil members |
US10305354B2 (en) | 2013-10-18 | 2019-05-28 | Atop S.P.A. | Apparatus for manufacturing components of dynamoelectric machines |
US10749418B2 (en) | 2015-04-30 | 2020-08-18 | Atop S.P.A. | Methods for forming woven undulated coil assemblies |
CN113314329A (en) * | 2021-06-17 | 2021-08-27 | 孙齐宏 | Three-phase 48-pulse rectifier transformer coil press machine suitable for high-low voltage electrical field |
US11557946B2 (en) | 2015-07-20 | 2023-01-17 | Atop S.P.A. | Method for inserting undulated coil assemblies in slots of cores of dynamoelectric machines |
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ITPI20080023A1 (en) | 2008-03-19 | 2009-09-20 | Atop Spa | EQUIPMENT AND METHODS FOR WINDING SUPPORTS FOR REELS AND SINGLE POLE NUCLEI FOR DYNAMIC ELECTRIC MACHINES |
IT1393157B1 (en) * | 2009-03-05 | 2012-04-11 | Atop Spa | EQUIPMENT FOR WINDING AND ASSEMBLING SUPPORTS FOR NUCLEUS COILS FOR DYNAMIC ELECTRIC MACHINES |
IT1400809B1 (en) * | 2010-06-21 | 2013-07-02 | Atop Spa | EQUIPMENT AND METHODS FOR WINDING SUPPORTS FOR REELS AND SINGLE POLE OF NUCLEI FOR DYNAMIC ELECTRIC MACHINES. |
IT1400810B1 (en) * | 2010-06-21 | 2013-07-02 | Atop Spa | EQUIPMENT AND METHODS FOR WINDING SUPPORTS FOR REELS AND SINGLE POLE OF NUCLEI FOR DYNAMIC ELECTRIC MACHINES BY APPLYING PRELIMINARY VOLTAGE ON THE WIRE. |
IT1400811B1 (en) * | 2010-06-21 | 2013-07-02 | Atop Spa | EQUIPMENT FOR WRAPPING SUPPORTS FOR REELS AND SINGLE POLES OF NUCLEI FOR DYNAMIC ELECTRIC MACHINES. |
ITPI20110078A1 (en) * | 2011-07-14 | 2013-01-15 | Atop Spa | EQUIPMENT AND METHODS FOR WRAPPING NUCLEI POLES FOR DYNAMIC ELECTRIC MACHINES |
DE102014220589A1 (en) * | 2014-10-10 | 2016-04-14 | Robert Bosch Gmbh | Method for deforming a winding in an electrical machine |
KR102072396B1 (en) * | 2017-09-29 | 2020-03-02 | 한국생산기술연구원 | Method and device for coil's winding |
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US9467029B2 (en) | 2010-06-21 | 2016-10-11 | Atop S.P.A. | Apparatus and method for winding supports for coils and single poles of cores for dynamoelectric machines |
US9455614B2 (en) | 2011-03-07 | 2016-09-27 | Atop S.P.A. | Method for aligning conductors of coil members |
US10224789B2 (en) | 2011-03-07 | 2019-03-05 | Atop S.P.A. | Apparatus for aligning conductors of coil members in cores of electric dynamo machines |
KR20140022030A (en) * | 2011-05-16 | 2014-02-21 | 어탑 에스.피.에이. | Apparatus and method for manufacturing coil members for cores of dynamo electric machines by bending |
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US9479033B2 (en) * | 2011-05-16 | 2016-10-25 | Atop S.P.A. | Apparatus and method for manufacturing coil members for cores of dynamo electric machines by bending |
KR102040749B1 (en) | 2011-05-16 | 2019-11-05 | 어탑 에스.피.에이. | Apparatus and method for manufacturing coil members for cores of dynamo electric machines by bending |
US10411570B2 (en) | 2011-05-16 | 2019-09-10 | Atop S.P.A. | Apparatus for manufacturing coil members for cores of dynamo electric machines by bending |
US10305354B2 (en) | 2013-10-18 | 2019-05-28 | Atop S.P.A. | Apparatus for manufacturing components of dynamoelectric machines |
US9692283B2 (en) | 2014-03-07 | 2017-06-27 | Atop S.P.A | Apparatus and method for forming coil members |
KR20160131056A (en) * | 2014-03-07 | 2016-11-15 | 어탑 에스.피.에이. | Apparatus and method for forming coil members |
KR102355130B1 (en) | 2014-03-07 | 2022-01-24 | 어탑 에스.피.에이. | Apparatus and method for forming coil members |
US10749418B2 (en) | 2015-04-30 | 2020-08-18 | Atop S.P.A. | Methods for forming woven undulated coil assemblies |
US11336160B2 (en) | 2015-04-30 | 2022-05-17 | Atop S.Pa. | Methods for forming woven undulated coil assemblies |
US11658553B2 (en) | 2015-04-30 | 2023-05-23 | Atop S.P.A. | Apparatuses for forming woven undulated coil assemblies |
US11557946B2 (en) | 2015-07-20 | 2023-01-17 | Atop S.P.A. | Method for inserting undulated coil assemblies in slots of cores of dynamoelectric machines |
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Also Published As
Publication number | Publication date |
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EP2266193B1 (en) | 2017-12-13 |
EP2266193A2 (en) | 2010-12-29 |
WO2009115312A2 (en) | 2009-09-24 |
CN101978582A (en) | 2011-02-16 |
KR20100138909A (en) | 2010-12-31 |
TR201802294T4 (en) | 2018-03-21 |
WO2009115312A3 (en) | 2009-12-23 |
ITPI20080023A1 (en) | 2009-09-20 |
US9543813B2 (en) | 2017-01-10 |
ES2664577T3 (en) | 2018-04-20 |
CN101978582B (en) | 2015-02-11 |
KR101392465B1 (en) | 2014-05-08 |
DK2266193T3 (en) | 2018-02-26 |
SI2266193T1 (en) | 2018-04-30 |
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